Continuous Improvement Toolkit. Fishbone Diagram. Continuous Improvement Toolkit

Continuous Improvement Toolkit Fishbone Diagram Continuous Improvement Toolkit . www.citoolkit.com The Continuous Improvement Map Deciding & Select...
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Continuous Improvement Toolkit Fishbone Diagram

Continuous Improvement Toolkit . www.citoolkit.com

The Continuous Improvement Map Deciding & Selecting

Managing PDPC Risk FMEA

Decision Balance Sheet

Cost Benefit Analysis

Break-even Analysis

Risk Assessment*

Fault Tree Analysis Decision Tree

Matrix Diagram

Kano Analysis

Cost of Quality* Pugh Matrix

Bottleneck Analysis**

OEE

Paired Comparison

Probability Distributions Gap Analysis* Reliability Analysis

MSA

Benchmarking**

Questionnaires

Data Collection

5 Whys

Control Charts

Data collection planner* Check Sheets

Run Charts

Sampling

Interviews

Observations

Understanding Cause & Effect

Root Cause Analysis

SCAMPER**

Document control

Cross Training

Implementing Solutions**

Value Analysis

Data Snooping

Visual Management

SIPOC*

Relationship Mapping*

Suggestion systems

Creating Ideas

Flow

Just in Time

Pull

Attribute Analysis

Lateral Thinking

Automation

TPM

Regression

How-How Diagram**

Mind Mapping*

Ergonomics

Mistake Proofing

Simulation

Confidence Intervals

Correlation

Morphological Analysis

Affinity Diagram

Control Planning

Standard work

Design of Experiment

Fishbone Diagram Tree Diagram*

Brainstorming

Focus Groups

Hypothesis Testing

Scatter Plots

Graphical Analysis

Understanding Performance

Chi-Square

Multi vari Studies

Histograms & Boxplots

Improvement Roadmaps

Kaizen Events A3 Thinking

ANOVA

Descriptive Statistics

Stakeholder Analysis

PDCA Policy Deployment Gantt Charts

C&E Matrix

Process Yield Capability Indices

DMAIC

Activity Networks

Prioritization Matrix

Pareto Analysis

KPIs

Project Charter

Portfolio Matrix

PERT/CPM

RACI Matrix

SWOT Analysis

Four Field Matrix

QFD

Daily Planning

MOST

TPN Analysis

Voting

Pick Chart

Critical-to Tree

Traffic Light Assessment Lean Measures

Importance-Urgency Mapping

Force Field Analysis

RAID Log*

Planning & Project Management*

5S

Waste Analysis Quick Changeover

Process Redesign

Spaghetti Diagram

Value Stream Mapping

Flow Process Charts

Flowcharting

IDEF0

Time Value Map

Service Blueprints Process Mapping

Designing & Analyzing Processes

Continuous Improvement Toolkit . www.citoolkit.com

- Fishbone Diagram 

  

Identifies and organizes the potential causes of a business problem. Uses an easy and understandable format. Used to identify the sources of process variation. It is also called Ishikawa Diagram and Cause and Effect Diagram.

Continuous Improvement Toolkit . www.citoolkit.com

- Fishbone Diagram  







Identifies the causes of an undesirable effect of a problem. It is also possible to identify the hierarchy of causes including the possible root causes. Brings attention to the primary factors affecting the quality of a product or service. These factors need to be optimized in order to reduce the amount of process variation. The outcome can provide initial information to later problem solving tools.

Continuous Improvement Toolkit . www.citoolkit.com

- Fishbone Diagram Root Causes are Normally:  Those at the ends of chains of causes.  They do not have any sub-causes. Primary Cause

Sub Cause

Cause

Effect / Problem

Continuous Improvement Toolkit . www.citoolkit.com

- Fishbone Diagram   

Often used during brainstorming sessions. Everyone gains insight into the cause and effect This makes the solution easier to find later on.

Continuous Improvement Toolkit . www.citoolkit.com

- Fishbone Diagram 

 



Helps to create ideas about the possible causes of a problem before it happens. An effective cause prevention tool. Helps to identify the potential factors causing an effect to prevent future problems. Can also be used in product design and to plan new processes.

Continuous Improvement Toolkit . www.citoolkit.com

- Fishbone Diagram 





Potential causes are sometimes called the process input variables. They are normally grouped into categories for easier sharing and reference. These are often called the 6 Ms.

Continuous Improvement Toolkit . www.citoolkit.com

- Fishbone Diagram 

Man – anyone involved with the process and contributes to the effect.



Methods – how the process is performed and the specific requirements for doing it, such as: • •

• •

Policies. Procedures. Rules. Common practices.

Continuous Improvement Toolkit . www.citoolkit.com

- Fishbone Diagram 

Machines – including the equipment and tools required to do the process.



Materials – The material needed to produce the product or provide the service, including: • •

• • •

Raw materials. Parts. Papers. Packing. Consumables. Continuous Improvement Toolkit . www.citoolkit.com

- Fishbone Diagram 

Environment (or Mother Nature) – the conditions in which the process operates such as: •

• • •



Location. Time. Temperature. Culture.

Measurements – including the data that are used to evaluate the performance of the process. Continuous Improvement Toolkit . www.citoolkit.com

- Fishbone Diagram 

Typical Fishbone Diagrams for Manufacturing and Nonmanufacturing Processes: Manpower

Environment

Machines

Manufacturing Materials

People

Measurement

Environment

Methods

Equipment

Administration and Services Policies and Procedures

Continuous Improvement Toolkit . www.citoolkit.com

- Fishbone Diagram How to Construct a Fishbone Diagram:  Clearly define the effect of the problem.  Write it down at the center right of a large piece of paper.  Determine the major categories of causes.  Write them on the branches of the diagram.  Use brainstorming to log all possible causes under the appropriate branches.  Use 5 Whys to search for root causes then add them to the diagram.

Continuous Improvement Toolkit . www.citoolkit.com

- Fishbone Diagram How to Construct a Fishbone Diagram:  Take time to ensure the appropriateness of the recorded information.  Update the chart as new causes become apparent.  Mark or assign numbers near to the key causes to show their relative priority.  Collect data and investigate to verify the key causes are actual.  Plan and implement actions to address the key causes.

Continuous Improvement Toolkit . www.citoolkit.com

- Fishbone Diagram Ways of Finding More Causes:  Keep asking questions to encourage everyone to participate.  Involve other people, especially those who have experience in the process.  Leave the chart on the wall for few days and encourage passers-by to contribute.  Take a break or do something to take the team’s mind off the current thoughts.

Continuous Improvement Toolkit . www.citoolkit.com

- Fishbone Diagram Example – The Increased Invoice Errors for a Company: Environment

Equipment

Poor ergonomics Noisy office

Method Cumbersome process

Inadequate printers

System incompatible

Manual data entry System not integrated

Paper quality

Poor audit system

Inadequate paper supply

Invoice Faults

Low morale

Inadequate validation process

Increased workload

Poor technical support Material

Measure

Man

Continuous Improvement Toolkit . www.citoolkit.com

- Fishbone Diagram Example – The Increased Coolant Consumption in a Factory: Environment

Machine Machine leakage

Evaporation in hot seasons

Biocide level Antifoam level

Material

Method Adjusting Concentration settings

Machine breakdown

Trench gets other materials

WBLF not measured per line separately

Adding WBLF to the tank directly Blocked hoses

Rounding measurement

Lack of training Poor communication between shifts

WBLF not measure on time

Measure

Man

Continuous Improvement Toolkit . www.citoolkit.com

High Coolant Consumption

- Fishbone Diagram Further Information:  Different names may be used for the same category. • •

 



Procedures could be used instead of Methods. Equipment could be used instead of Machines.

You may even create your own branches that suit your needs. An affinity diagram could be used to create the branches of the diagram from the titles of the affinity sets. Don’t overload categories. •

Establish another category if needed.

Continuous Improvement Toolkit . www.citoolkit.com

- Fishbone Diagram Further Information:  You could also create sub categories under the main categories.  For example, under Man there might be: • •

• •



Poor Communication Absenteeism Lack of Training …

You should, however, avoid writing real names of persons.

Continuous Improvement Toolkit . www.citoolkit.com

- Fishbone Diagram Further Information:  Beware of adding causes which are actually solutions.  A Cause and Effect Matrix could be used to prioritize the causes of the problem.  Prioritizing and selecting the key causes will minimizes the need for more statistical evaluation of inputs that are unlikely to have an impact on the output. Y1 Y2 Y3 Y4 X1





X2 

X3   X4

Continuous Improvement Toolkit . www.citoolkit.com

 

- Fishbone Diagram Further Information: Example – Making Tea Cause and Effect Matrix: Cause / Effect

Taste

Volume

Temperature





6





13

The boil kettle Adding water



Adding tea



9

Adding sugar



3

Adding milk



Stirring







11 3

25

7

13

Symbol







Value

9

3

1

Relationship

Strong

Medium

Weak

Continuous Improvement Toolkit . www.citoolkit.com